Complete Guide to Metal Manufacturing Methods: Die Casting, Forging, Machining and More

Comparing Common Metal Manufacturing Processes: Die Casting, Forging, Machining & More

Metal parts production relies on a variety of manufacturing techniques, each suited for different needs in terms of strength, precision, cost, and complexity. 

Whether you are sourcing high-quality components for heavy equipment, industrial machines, or consumer electronics, understanding the differences among these methods is crucial for choosing the right supplier and process. 

Below is a detailed comparison of some of the most common metal forming and machining processes.

Die Casting vs. Sand Casting

Die Casting

Die casting involves injecting molten metal into a steel mold under high pressure. 

This method is ideal for mass production of parts requiring excellent surface finish and tight dimensional tolerances. 

The molds are durable and reusable, typically made from high-strength steel alloys. 

It is commonly used for automotive parts, electronics housings, and complex machinery components.

Sand Casting

Sand casting uses expendable sand molds formed around a pattern. 

It’s a cost-effective option for low-volume or large-size metal parts. 

While it does not provide the same surface finish or precision as die casting, it allows for more flexibility in shape and scale, making it popular in heavy machinery and industrial equipment manufacturing.

Investment Casting & Centrifugal Casting

Investment Casting

Also known as lost-wax casting, this technique is ideal for producing parts with intricate details. 

A wax model is coated with ceramic material to form a mold. 

After melting the wax out, molten metal is poured in. 

Investment casting is widely used in aerospace, medical tools, and precision machinery.

Centrifugal Casting

This process uses a rotating mold to distribute molten metal through centrifugal force. 

It's ideal for cylindrical parts like pipes and bushings, ensuring a dense, defect-free structure.

Forging, Rolling, and Drawing

Forging

Forging applies pressure to deform metal into a desired shape. 

Die forging, hammer forging, and roll forging improve the mechanical properties of parts. 

This method is preferred for high-stress components such as gears, shafts, and aerospace parts.

Rolling & Drawing

Rolling reduces metal thickness through rollers, often done at high temperatures (hot rolling) or room temperature (cold rolling). 

Drawing pulls metal through dies to produce wires, tubes, and precision rods. Both methods are efficient for mass production.

Machining Processes: Turning, Milling, Grinding & More

Turning

Turning rotates the workpiece while a stationary cutting tool shapes it. 

It's suitable for cylindrical parts like shafts and bushings and is common in repair shops and manufacturing lines.

Milling & CNC Machining

Milling uses rotary cutters to remove material. Modern CNC milling machines allow 3-axis or multi-axis precision cutting for complex parts such as molds, impellers, and aerospace components.

Grinding & Planing

Grinding ensures smooth, precision finishes, especially after primary processing. 

Planing removes excess material through linear cutting and is ideal for flat surfaces and large parts.

Advanced Forming Technologies

Metal Injection Molding (MIM)

Combining plastic injection molding and powder metallurgy, MIM is used to manufacture small, complex, high-strength metal parts, especially in medical, electronics, and military industries.

Squeeze Casting & Continuous Casting

Squeeze casting fills molds under pressure, ensuring excellent density and structure, suitable for automotive parts. 

Continuous casting allows for uninterrupted metal production, maximizing efficiency in billet and slab manufacturing.

Why Choose Us as Your Metal Parts Supplier?

At our company, we specialize in supplying custom and standard components produced through die casting, forging, machining, and other methods. 

Whether you need small precision parts or large industrial castings, we offer high-quality manufacturing at competitive prices, tailored to your specifications.

•  Full in-house Quality Control
•  OEM & ODM support
•  Global shipping and fast turnaround
•  Technical engineering support

Conclusion

Understanding the strengths of different metal forming techniques allows you to make informed decisions when sourcing parts. 

Whether you need tight tolerance components, high-strength forged parts, or affordable large castings, we can help deliver the right product for your application.